Modified gel particles and rubber composition

ABSTRACT

This invention discloses a process for synthesizing a modified crosslinked elastomeric particle which comprises a two-step polymerization of a conjugated diolefin monomer and a vinyl aromatic monomer by emulsion polymerization, wherein the particle is synthesized by the steps of (1) polymerizing a conjugated diolefin monomer, alone or in combination with a vinyl aromatic monomer, and optionally a crosslinking monomer, to create a crosslinked elastomeric core having residual double bonds and an outer surface; (2) polymerizing a monomer of a vinyl aromatic monomer, alone or in combination with a diolefin monomer, to create a polymeric shell, wherein the polymeric shell is grafted to the outer surface of the polymeric core by reacting with the residual double bonds of the polymeric core; and (3) coagulating the core-shell emulsion latex solution to recover the particles.

This is a divisional and a continuation-in-part application of U.S.patent application Ser. No. 10/999,406 filed on Nov. 30, 2004. Theteachings of U.S. patent application Ser. No.10/999,406 are incorporatedherein by reference in their entirety.

BACKGROUND OF THE INVENTION

Particles of various types are commonly incorporated into rubbercompositions as fillers. For instance, fillers are typically included inthe rubber compositions utilized in manufacturing tires, hoses, belts,windshield wiper blades, floor mats, and other rubber products. Thefillers are chosen to enhance certain physical characteristics of therubber composition. Especially in tire art, the use of carbon black,silica, and crosslinked polymers as fillers is well known. The additionof fillers tends to improve the physical properties of the polymermatrices to which they are added. For instance, the inclusion of carbonblack and silica in tire tread rubber compounds is critical to attainrequired strength and tread wear characteristics. However, such tireshave the disadvantage that they have a high rolling resistance, which isrelated to hysteresis loss. With the increasing demand for automobilesafety and low fuel consumption, the specifications for tire treadelastomeric compounds have become more critical. Tire treads areexpected to have high abrasion resistance in order to provide a longlife expectancy, to exhibit good anti-skid properties in both wet anddry conditions, and to have low hysteresis characteristics at elevatedtemperatures in order to provide low rolling resistance and reduceddynamic heat build-up. Therefore, numerous attempts have been made inthe design of both elastomer matrices and fillers.

U.S. Pat. No. 5,395,891 and U.S. Pat. No. 6,127,488 to Obrecht disclosethe use of crosslinked polybutadiene and crosslinked styrene-butadienecopolymers, respectively, as fillers. The purported benefit of theinclusion of these crosslinked rubber particles in rubber formulationsis lower hysteresis. Additionally, polybutadiene gels have been shown toimpart improved abrasion resistance while styrene-butadiene copolymergels have demonstrated improved wet traction characteristics. U.S. Pat.No. 6,133,364, U.S. Pat. No. 6,207,757, and U.S. Pat. No. 6,242,534 toObrecht et al disclose a rubber composition comprising a crosslinkedelastomer particle and a non-crosslinked elastomer. The crosslinkedelastomeric particles are functionalized to impart unique surfacereactivity for improved coupling with the non-crosslinked host elastomeras well as the subsequent ability to employ coupling agents other thanthe conventional sulfur-bridged bis-alkoxy silanes. The benefits ofthese gels in tire tread compositions are reported to be lowerhysteresis, improved abrasion resistance, and improved wet traction.However, using these gel particles as fillers shows some criticaldrawbacks such as inferior mechanical properties (e.g. 300% moduli, tearand abrasion resistance). U.S. Pat. No. 6,620,866 discloses a rubbermixture containing agglomerated rubber gels. The purpose of using thehigh-pressure agglomerated gels is to improve the recognized deficiencyin the mechanical properties.

U.S. Pat. No. 6,747,095 and U.S. Pat. No. 6,653,404 to Konno et aldisclose a rubber composition comprising as essential components acrosslinked polymer particle and a non-crosslinked rubber component. Therubber composition may be used to obtain a vulcanized rubber. Thecrosslinked polymer particles are intended for use as filler to providea rubber composition having good processability and handling performanceas well as improved tensile strength and wear resistance whenvulcanized.

SUMMARY OF THE INVENTION

The present invention relates to core-shell type emulsion polymerparticles and methods for preparing them. The core-shell polymerparticle is comprised of a crosslinked elastomeric center portion (core)and an exterior portion (shell) which has a composition that issufficiently different from the core. The core-shell polymer particlescan be prepared with a controlled structure and size. The function ofthe crosslinked core is to provide a discrete polymer phase having aglass transition temperature which imparts better wet traction and lowerrolling resistance. The advantage over the prior art is the inclusion ofa vinyl aromatic-rich shell to the core. This modification has beenfound to impart improved mechanical and tear properties of a rubberycomposite compared to the crosslinked elastomeric core alone.Specifically the present invention relates to mixtures of rubberscontaining crosslinked elastomeric particles (diolefins and copolymersconsisting of vinyl aromatic monomers and diolefins) grafted with avinyl aromatic polymer or copolymer of vinyl aromatic monomers anddiolefins, which can form a core-shell type structure. The particles aregenerally described to be composed of a crosslinked elastomeric core anda shell, where the shell is covalently connected to the core. Thecrosslinked elastomeric core may be designed to have a composition whichprovides high damping in a particular temperature range so as to impartimproved wet traction, and usually low damping at higher temperatures,for improved rolling resistance. The advantage of the current inventionis that the vinyl aromatic-rich shell reinforces the crosslinkedelastomeric core, which enhances mechanical properties, e.g., highelastic modulus. In addition, the vinyl aromatic-rich shell is believedto increase the interactions between the particles to obtain better tearresistance.

The core-shell particles of polystyrene and polybutadiene are disclosedin U.S. Pat. No. 6,777,500. The shell is grafted onto the core throughlinkage with residual unreacted vinyl groups carried in the core. Thecore-shell particle comprises a crosslinked polymer core where thecrosslinked polymer core has a predetermined glass transitiontemperature (T_(g)) such that the crosslinked polymer core does notsoften at service temperatures up to about 150° C.

The core-shell particle is also disclosed as a “hairy particle” asdescribed in U.S. Provisional Patent Application Ser. No. 60/552,617,filed on Mar. 12, 2004. The hairy polymer particles can be synthesizedby first making a core polymer by emulsion polymerization. After beingdried, the core polymer is reacted with an organo-lithium compound tomake a hairless core initiator. The hairless core initiator can then beused to initiate the anionic polymerization of conjugated diolefinmonomers to produce the hairy polymer particles of this invention. Thefinal structured core-shell particle has a crosslinked core and a shellcontaining linear polymer brushes.

Core-shell particles are widely used for rubber toughened plastics andadhesives. Core-shell morphologies from polybutadiene-polystyrene graftcopolymers are taught by U.S. Pat. No. 6,248,419 and U.S. Pat. No.6,489,378 to Sosa et al. But, the teaching is directed to production ofhigh impact polystyrene using graft copolymer particles having apolystyrene core occluded inside a polybutadiene shell and the particleshave an average particle size of about 0.5 microns. U.S. Pat. No.5,686,528 by Wills et al disclosed high-impact poly(styrene) resinsmodified with small particle size below 250 nm, multi-stage impactmodifiers having a crosslinked poly(butadiene) core and a poly(styrene)or other vinyl-aromatic polymer shell. The additive polymer is useful inimproving the balance of impact strength and other physical propertiessuch as gloss, stiffness and resistance to environmental stress crazingwhen blending with thermoplastics.

The present invention is the result of the discovery that crosslinkedelastomeric polymer particles (diolefins, and copolymers consisting ofvinyl aromatic monomers and diolefins) can be augmented by a vinylaromatic-rich shell, and the resulting modified, crosslinked elastomericpolymer particles can be used as fillers to provide enhanced mechanicaland dynamical properties of rubber composites. The vinyl aromatic-richshell has a composition which is sufficiently different from thecrosslinked elastomeric core that the particle assumes a core-shell typestructure.

The core and the shell can be varied depending upon the desiredproperties and use of the particles. The core and shell may be comprisedof diolefins and vinyl aromatics monomers or mixtures thereof. The corecan be crosslinked using a multi-functional monomer. The core may alsobe crosslinked when diene monomers are used and the reaction is allowedto proceed to high conversion. The shell can be grafted onto the corethrough linkages with residual unreacted double bonds carried in thecore. The volume fraction of the core and shell can be varied dependingupon the desired final properties of the particles. The shellcomposition can be chosen to provide compatibility or incompatibilitywith the matrix composition. The core-shell particle may comprise acrosslinked polymer core where the crosslinked polymer core has apredetermined glass transition temperature (T_(g)) such that thecrosslinked rubber gels provide improved wet traction.

The particles are synthesized by emulsion polymerization which can be abatch, semi-batch, or continuous process, but which provides control ofthe polymer composition and morphology. The process produces particleshaving a mean average diameter of less than 200 nm, preferably less thanabout 100 nm. The core-shell particles are useful as fillers in polymercompositions and the particles of the present invention provide enhancedproperties for the polymer compositions.

The subject invention more specifically discloses a core-shell typeparticle which is comprised of (1) a crosslinked elastomeric corecomprised of repeat units that are derived from at least one diolefinmonomer and optionally one or more vinyl aromatic monomer, and (2) apolymeric shell which is derived from at least one vinyl aromaticmonomer.

The subject invention further discloses a process for synthesizing amodified crosslinked elastomeric particle which comprises a two-steppolymerization of a conjugated diolefin monomer and a vinyl aromaticmonomer by emulsion polymerization, wherein the particle is synthesizedby the steps of (1) polymerizing a conjugated diolefin monomer, alone orin combination with a vinyl aromatic monomer, and optionally acrosslinking monomer, to create a crosslinked elastomeric core havingresidual double bonds and an outer surface; (2) polymerizing a monomerof a vinyl aromatic monomer, alone or in combination with a diolefinmonomer, to create a polymeric shell, wherein the polymeric shell isgrafted to the outer surface of the polymeric core by reacting with theresidual double bonds of the polymeric core; and (3) coagulating thecore-shell emulsion latex solution to recover the particles.

The present invention further reveals a rubber composition which iscomprised of a rubbery polymer and a core-shell polymer particle,wherein the core-shell polymer particle is comprised of (1) a core whichis comprised of a polymer of a diolefin monomer and (2) a shell which iscomprised of a vinyl aromatic monomer, wherein the shell is covalentlybonded to the core.

The subject invention also discloses a process for making a rubbercomposition containing a core-shell polymer which comprises the steps of(1) polymerizing a conjugated diolefin monomer, alone or in combinationwith a vinyl aromatic monomer, and optionally a crosslinking monomer, tocreate a polymeric core having residual double bonds and an outersurface; (2) polymerizing a vinyl aromatic monomer, alone or incombination with a diolefin monomer, to create a polymeric shell,wherein the polymeric shell is grafted covalently to the outer surfaceof the polymeric core to produce a latex of the core-shell polymer; (3)blending the latex of the core-shell polymer with a latex of a rubberypolymer to produce a latex blend, and (4) coagulating the latex blend torecover the rubber composition.

The present invention further reveals a tire which is comprised of agenerally toroidal-shaped carcass with an outer circumferential tread,two spaced beads, at least one ply extending from bead to bead andsidewalls extending radially from and connecting said tread to saidbeads, wherein said tread is adapted to be ground-contacting, andwherein said tread is comprised of (1) a filler, (2) a rubbery polymer,and (3) core-shell particles that are comprised of (a) a crosslinkedelastomeric core comprised of repeat units that are derived from atleast one diolefin monomer and optionally one or more vinyl aromaticmonomer, and (b) a polymeric shell which is derived from at least onevinyl aromatic monomer.

DETAILED DESCRIPTION OF THE INVENTION

The modified gel particles of this invention are synthesized by emulsionpolymerization in the following steps: (1) polymerizing to highconversion a conjugated diolefin monomer, alone or in combination with avinyl aromatic monomer, and optionally a crosslinking monomer, to createan unsaturated, crosslinked polymeric core. Upon obtaining a highconversion of the first monomer charge, a vinyl aromatic monomer, aloneor in combination with a diolefin monomer is added to the reactionmixture and the entire monomer charge is taken to full conversion tocreate a polymer composition at the exterior of the particle which issufficiently different from the crosslinked elastomeric core to producea shell-type structure, preferably wherein the polymeric shell isgrafted covalently to the outer surface of the polymeric core. Theintent of using a vinyl aromatic monomer alone or in combination with adiolefin monomer is to modify the properties of the crosslinkedelastomeric core.

A glass transition temperature of −20° C. to 20° C. is preferred for thecrosslinked elastomeric core with the shall having a glass transitiontemperature of 20° C. or above. It is important for the core polymer tohave a glass transition temperature within the range of −20° C. to 20°C. to attain high traction characteristics when used in tire treadcompounds. The shell will typically be comprised of a polymer having aglass transition temperature that is within the range of 50° C. to 160°C. When the crosslinked elastomeric core and the shell are incompatiblewith each other, phase separation occurs with the result being acore-shell type structure. The glass transition temperature of thepolymer making up the shell will accordingly differ from that of thecore by at least 30° C., preferably at least 50° C., and most preferablyat least 70° C. It is desirable for this difference in glass transitiontemperatures to be as great as possible to attain lower rollingresistance when utilized in tire tread compounds.

The weight ratio of the polymer comprising the core to polymercomprising the shell will typically be within the range of 20:1 to 1:1.The weight ratio of the core to the shell will more typically be withinthe range of 15:1 to 7:1 and will preferably be within the range of 12:1to 8:1. Accordingly, in synthesizing the core-shell polymer the weightratio of the monomer charge used in making the core to the monomercharged used in making the shell will typically be within the range of20:1 to 1:1, will more typically be within the range of 15:1 to 7:1, andwill preferably be within the range of 12:1 to 8:1.

The crosslinked elastomeric polymer core and the vinyl aromaticcontaining shell are synthesized by the emulsion polymerization of vinylaromatic monomers, and optionally, conjugated diolefin monomers.Generally, any vinyl aromatic monomer which is known to polymerize withfree radical initiators can be used. Such vinyl aromatic monomerstypically contain from 8 to 20 carbon atoms. Usually, the vinyl aromaticmonomer will contain from 8 to 14 carbon atoms. The most widely usedvinyl aromatic monomer is styrene. Some examples of vinyl aromaticmonomers that can be utilized include styrene, 2-methylstyrene,3-methylstyrene, 4-methylstyrene, α-methyl styrene, 2,4-dimethylstyrene,2,4-diisopropylstyrene, 4-tert-butylstyrene, 1-vinylnaphthalene,2-vinylnaphthalene, α-methylstyrene, 4-phenylstyrene, 3-methylstyreneand the like. The conjugated diolefin monomers that can optionally beincluded in synthesizing the core polymer typically contain from 4 to 12carbon atoms. Those containing from 4 to 8 carbon atoms are generallypreferred for commercial purposes. For similar reasons, 1,3-butadieneand isoprene are the most commonly utilized conjugated diolefinmonomers. Some additional conjugated diolefin monomers that can beutilized include 2,3-dimethyl-1,3-butadiene, piperylene,3-butyl-1,3-octadiene, 2-phenyl-1,3-butadiene, and the like, alone or inmixture. The choice of monomers and ratio of vinyl aromatic monomers toconjugated diolefin monomer used in making the core polymer will dependupon the properties desired for the polymer particles being made.However, the shell polymer will normally be comprised of at least 75weight percent vinyl aromatic monomers and will more typically becomprised of at least 80 weight percent vinyl aromatic monomers. It isnormally preferred for the shell to be comprised of at least 90 weightpercent vinyl aromatic monomers and can be made entirely of vinylaromatic monomers.

The core particles will typically be crosslinked using a crosslinkingmonomer unit such as divinyl benzene, diisopropenylbenzene, or1,2-polybutadiene. The crosslinking monomer will typically beincorporated at a level which is within the range of 0% to about 100%,preferably about 10% to about 30%, and most preferably 15% to 25% byweight based upon the weight of the polymer. In some case it isdesirable to crosslink the polymeric core to a higher level utilizingfrom 20% to 30% of the crosslinking monomer based upon the weight of thepolymer. Crosslinking the particle can increase the hardness of thecore, as well as glass transition temperature of the nanoparticle.

The emulsion polymerization is conducted as a batch, semi-continuous, orcontinuous operation. Essentially any type of free radical generator canbe used to initiate the free radical emulsion polymerization. Forexample, free radical generating chemical compounds, ultra-violet lightor radiation can be used. In order to ensure a satisfactorypolymerization rate, uniformity and a controllable polymerization, freeradical generating chemical agents which are water-soluble oroil-soluble under the polymerization conditions are generally used withgood results.

Some representative examples of free radical initiators which arecommonly used include the various peroxygen compounds such as potassiumpersulfate, ammonium persulfate, benzoyl peroxide, hydrogen peroxide,di-t-butyl peroxide, dicumyl peroxide, 2,4-dichlorobenzoyl peroxide,decanoyl peroxide, lauryl peroxide, cumene hydroperoxide, p-menthanehydroperoxide, t-butyl hydroperoxide, acetyl acetone peroxide, dicetylperoxydicarbonate, t-butyl peroxyacetate, t-butyl peroxymaleic acid,t-butyl peroxybenzoate, acetyl cyclohexyl sulfonyl peroxide, and thelike; the various azo compounds such as 2-t-butylazo-2-cyanopropane,dimethyl azodiisobutyrate, azodiisobutyronitrile,2-t-butylazo-1-cyanocyclohexane, 1-t-amylazo-1-cyanocyclohexane, and thelike; the various alkyl perketals, such as2,2-bis-(t-butylperoxy)butane, ethyl 3,3-bis(t-butylperoxy)butyrate,1,1-di-(t-butylperoxy)cyclohexane, and the like. Persulfate initiators,such as potassium persulfate and ammonium persulfate, are especiallyuseful in such aqueous emulsion polymerizations.

The core and shell polymers of this invention can also be synthesizedwith free radicals that are generated utilizing redox initiators, suchas combinations of chelated iron salts, sodium formaldehyde sulfoxylate,and organic hydroperoxides. Some representative examples of such organichydroperoxides include cumene hydroperoxide, paramenthane hydroperoxide,and tertiary butyl hydroperoxide. Tertiary butyl hydroperoxide (t-BHP),tertiary butyl peracetate (t-BPA) and “azo” initiators, such asazobisiobutyronitrile (AIBN), are preferred for use in generating freeradicals.

The amount of free radical initiator employed will vary with the desiredmolecular weight of the core particle being synthesized. Highermolecular weights are achieved by utilizing smaller quantities of theinitiator and lower molecular weights are attained by employing largerquantities of the initiator. However, as a general rule, from 0.005 to 1phm (parts by weight per 100 parts by weight of monomer) of theinitiator will be included in the reaction mixture. In the case of metalpersulfate initiators, typically from 0.1 phm to 0.5 phm of theinitiator will be employed in the polymerization medium. A chaintransfer agent, such as t-dodecyl mercaptan, can optionally be used toreduce the molecular weight of the polymer synthesized during theemulsion polymerization used to make the polymeric core. For instance,the molecular weight of the core polymer reduces with increasing levelsof chain transfer agent. However, it is not necessary to utilize a chaintransfer agent in the synthesis of the core polymer.

In batch operations, the polymerization time can be varied as desired;it may vary, for example, from a few minutes to several days.Polymerization in batch processes may be terminated when monomer is nolonger absorbed, or earlier, if desired, e.g., if the reaction mixturebecomes too viscous. In continuous operations, the polymerizationmixture may be passed through a reactor system of any suitable design.The polymerization reactions in such cases are suitably adjusted byvarying the residence time. Residence times vary with the type ofreactor system and the size of the reactors, for example, from 10 to 15minutes to 24 or more hours.

Conventional emulsion recipes may also be employed with the presentinvention; however, some restrictions and modifications may arise eitherfrom the polymerizable monomer itself, or the polymerization parameters.Ionic surfactants, known in the art, including sulfonate detergents andcarboxylate, sulfate, and phosphate soaps are useful in this invention.The level of ionic surfactant is computed based upon the total weight ofthe organic components and may range from about 2 to 30 parts by weightof ionic surfactant per 100 parts by weight of organic components.

The soap systems used in the emulsion polymerization process willfrequently contain a combination of rosin acid and fatty acidemulsifiers. The weight ratio of fatty acid soaps to rosin acid soapswill typically be within the range of about 50:50 to 90:10. It isnormally preferred for the weight ratio of fatty acid soaps to rosinacid soaps to be within the range of 60:40 to 85:15. It is normally morepreferred for the weight ratio of fatty acid soaps to rosin acid soapsto be within the range of 75:25 to 82:18. All of the soap is typicallycharged into the first polymerization zone. The total amount of soapemployed will normally be less than 5 phm. The quantity of soap employedwill normally be within the range of about 1 phm to 4 phm. It istypically preferred to utilize a level of soap which is within the rangeof about 2 phm to about 3.0 phm. The precise amount of the soap systemrequired in order to attain optimal results will, of course, vary withthe specific soap system being used. However, persons skilled in the artwill be able to easily ascertain the specific amount of soap systemrequired in order to attain optimal results.

After the polymerization has been terminated, the core-shell polymer isrecovered from the aqueous medium. This can be accomplished bycoagulating the latex and recovering the core-shell polymer from theaqueous medium. The coagulation can be accomplished by adding an acid orpreferably a combination of salts and an acid to the emulsion. Followingthe initial coagulation, the core polymer may be washed one or multipletimes with water.

The core-shell particles can be incorporated in a non-crosslinked hostor matrix polymer where the non-crosslinked host polymer can be apolymer having only conjugated diene repeat units, a polymer havingrepeat units of a conjugated diene unit and an aromatic vinyl unit, apolymer having repeat units of a conjugated diene unit and anα,β-unsaturated nitrile unit, an acrylic rubber, a polymer having repeatunits of an ethylene unit, and polymers having repeat units havingfunctional groups able to interact with at least one functional group ofthe hairy polymer particles. Thus, the particles of the presentinvention are suitable for incorporation in and modifying a variety ofrubbers, including, but not limited to, random styrene-butadiene rubber(SBR) polybutadiene rubber, synthetic polyisoprene rubber, nitrilerubber, polyurethane, butyl rubber, EPDM, natural rubber, and the like.

The particles of this invention will typically be incorporated inrubbery polymers at a level which is within the range of about 5 phr(parts by weight per 100 parts by weight of the rubber) to about 100phr. The particles will more typically be utilized at levels which arewithin the range of 10 phr to 60 phr. The polymer particles of thisinvention can be used in conjunction with conventional rubbercompounding chemicals and in conjunction with conventional fillers, suchas carbon black, silica, and/or starch.

In one embodiment of this invention, the polymeric nanoparticles areincorporated into rubbery polymers by a technique that involves (1)blending the solution of the hairy polymer particles made by the processof this invention with the cement of a rubbery polymer to produce acement blend, and (2) coagulating the cement blend to recover the rubbercomposition. The utilization of this technique can further improve thelevel of incorporation and interaction between the nanoparticles and therubbery polymer. This can accordingly further improve the physicalproperties of the rubber composition.

The core-shell polymer particles of the present invention can be usedalone or in combination with other elastomers to prepare rubbercompounds, such as a tire treadstock, sidewall stock or other tirecomponent stock compounds. In a tire of the invention, at least one suchcomponent is produced from a vulcanizable elastomeric or rubberycomposition. For example, the core-shell polymer particles made by theprocess of this invention can be blended with any conventionallyemployed treadstock rubber which includes natural rubber, syntheticrubber and blends thereof. Such rubbers are well known to those skilledin the art and include synthetic polyisoprene rubber, styrene/butadienerubber (SBR), polybutadiene, butyl rubber, ethylene/propylene rubber,ethylene/propylene/diene rubber (EPDM), acrylonitrile/butadiene rubber(NBR), silicone rubber, the fluoroelastomers, ethylene acrylic rubber,ethylene vinyl acetate copolymer (EVA), epichlorohydrin rubbers,chlorinated polyethylene rubbers, chlorosulfonated polyethylene rubbers,hydrogenated nitrile rubber, tetrafluoroethylene/propylene rubber andthe like. In making tire tread compounds the core-shell polymerparticles will typically be blended with at least one rubbery polymerincluding natural rubber, polybutadiene rubber, styrene-butadienerubber, synthetic polyisoprene rubber (including 3,4-polyisoprene),isoprene-butadiene rubber, and styrene-isoprene-butadiene rubber. Thecore-shell polymer particles will typically be blended into the rubberypolymer at a level of 1 phr (parts by weight per 100 parts by weight ofrubber) to 50 phr. More typically the core-shell polymer particles willbe blended into the rubbery polymer at a level of 10 phr to 40 phr andwill preferable be included at a level of 20 phr to 30 phr.

The tire tread compounds made with the core-shell particles of thisinvention can be compounded with carbon black, silica, starch and/orother fillers in amounts ranging from about 5 to about 100 phr (parts byweight per 100 parts by weight of rubber), with about 5 to about 80 phrbeing preferred, and with about 40 to about 70 phr being more preferred.The carbon blacks may include any of the commonly available,commercially-produced carbon blacks but those having a surface area(EMSA) of at least 20 m²/g and more preferably at least 35 m²/g up to200 m²/g or higher are preferred. Surface area values used in thisapplication are those determined by ASTM test D-1765 using thecetyltrimethyl-ammonium bromide (CTAB) technique. Among the usefulcarbon blacks are furnace black, channel blacks and lamp blacks. Morespecifically, examples of the carbon blacks include super abrasionfurnace (SAF) blacks, high abrasion furnace (HAF) blacks, fast extrusionfurnace (FEF) blacks, fine furnace (FF) blacks, intermediate superabrasion furnace (ISAF) blacks, semi-reinforcing furnace (SRF) blacks,medium processing channel blacks, hard processing channel blacks andconducting channel blacks. Other carbon blacks which may be utilizedinclude acetylene blacks. Mixtures of two or more of the above blackscan be used in preparing the carbon black products of the invention.Typical values for surface areas of usable carbon blacks are summarizedin the following table. Carbon Black ASTM Designation (D-1765-82a)Surface Area (D-3765) N-110 126 m²/g  N-220 111 m²/g  N-330 83 m²/gN-339 95 m²/g N-550 42 m²/g N-660 35 m²/g

The carbon blacks utilized in the preparation of rubber compounds may bein pelletized form or an unpelletized flocculent mass. Preferably, formore uniform mixing, unpelletized carbon black is preferred. Thereinforced rubber compounds can be cured in a conventional manner withabout 0.5 to about 4 phr of known vulcanizing agents. For example,sulfur or peroxide-based curing systems may be employed. For a generaldisclosure of suitable vulcanizing agents one can refer to Kirk-Othmer,Encyclopedia of Chemical Technology, 3rd ed., Wiley Interscience, NewYork 1982, Vol. 20, pp. 365-468, particularly “Vulcanization Agents andAuxiliary Materials” pp. 390-402. Vulcanizing agents can, of curse, beused alone or in combination. Vulcanizable elastomeric or rubbercompositions can be prepared by compounding or mixing the polymersthereof with carbon black and other conventional rubber additives suchas fillers, plasticizers, antioxidants, curing agents and the like,using standard rubber mixing equipment and procedures and conventionalamounts of such additives.

This invention is illustrated by the following examples that are merelyfor the purpose of illustration and are not to be regarded as limitingthe scope of the invention or the manner in which it can be practiced.Unless specifically indicated otherwise, parts and percentages are givenby weight.

EXAMPLE I Preparation of Polystyrene Reinforced Polyisoprene Gels (PI-PSCore-Shell, Particle A)

A 10 gallon (38 liter) reactor equipped with two axial flow turbinesoperating at 220 rpm was evacuated for 30 minutes and then charged witha soap solution composed of 41.1 lbs (18.6 kg) of reverse osmosis (RO)water, 25.3 grams or tripotassium phosphate, 6.33 lbs (2.87 kg) of a 10%solution of C₁₄-C₁₈ unsaturated fatty acid potassium salt, 239 grams ofa 20% solution of the potassium salt of disproportionated rosin acid,52.3 grams of a 47.5% active dispersion of sodiumnaphthalenesulfonate-formaldehyde. The pH of the soap solution wasadjusted to 10.5-11.0 with a 20% potassium hydroxide solution.

To the reactor was added an activator solution composed of 440 grams ofRO water, 12.9 grams of hydroxymethane-sulfinic acid monosodium saltdihydrate, and 3.79 grams of ethylenediaminetetraacetic acid, ferricsodium complex. Then, 17.64 lbs (8.0 kg) of isoprene and 6.61 lbs (3.0kg) of 55% divinyl benzene were added to the reactor. The reactor wascooled to a temperature of 10° C. (50° F.). When the contents of thereactor reached 10° C. (50° F.), 30.0 grams of a 55% active pinanehydroperoxide was added. The reaction was allowed to proceed until thesolids content reached full conversion (˜30% solids). The reactor wasthen charged with 1100 grams of styrene and 15 grams of pinanehydroperoxide. The reaction was allowed to proceed until 100% monomerconversion was attained at a solids content of about 32% at which pointthe polymerization was stopped by the addition of 44 grams of 15% activeN-Isopropylhydroxylamine. The latex was degassed and steam strippeduntil the residual isoprene level was reduced to less than 500 parts permillion (ppm).

The latex was then stabilized by the addition of about 1%, based uponthe total weight of polymers, of a tri(mixed mono &dinonylphenyl)phosphite antioxidant. The latex was then coagulated in asolution containing 120 lbs (54.4 kg) of RO water and 4 lbs (1.8 kg) ofsodium chloride which had been adjusted to a pH of 3.5 with sulfuricacid by slowly adding the latex to the water/salt solution. The coagulumwas washed twice with RO water and dried at 60° C. (140° F.) in a forcedair oven.

EXAMPLE II Preparation of Polyisoprene Control Sample Core (Particle B)

A 2 gallon (7.57 liter) reactor equipped with two axial flow turbinesoperating at 220 rpm was evacuated for 30 minutes and then charged witha soap solution composed of 7.47 lbs (3.39 kg) of reverse osmosis (RO)water, 4.6 grams of tripotassium phosphate, 522 grams of a 10% solutionof C14-18 unsaturated fatty acid potassium salt, 43.5 grams of a 20%solution of the potassium salt of disproportionated rosin acid, 9.52grams of a 47.5% active dispersion of sodiumnaphthalenesulfonate-formaldehyde. The pH of the soap solution wasadjusted to 10.5-11.0 with a 20% potassium hydroxide solution.

To the reactor was added an activator solution composed of 80 grams ofRO water, 2.35 grams hydroxymethane-sulfinic acid monosodium saltdihydrate, and 0.69 grams of ethylenediaminetetraacetic acid, ferricsodium complex. Then, 1,454 grams of isoprene and 545 grams of 55%divinyl benzene were then added to the reactor. The reactor was cooledto 10° C. (50° F.). When the contents of the reactor reached 10° C. (50°F.), 5.45 grams of a 55% active pinane hydroperoxide was added. Thereaction was allowed to proceed until 100% conversion of the monomer atabout 30% solids and stopped by addition of 8 grams of 15% activeN-Isopropylhydroxylamine. The latex was degassed and steam strippeduntil the residual isoprene level was less than 500 parts per million(ppm).

To the latex was added about 1% of total weight of polymers tri(mixedmono & dinonylphenyl)phosphite antioxidant. The latex was thencoagulated in a solution of 60 lbs RO water at ˜70° C. (˜158° F.) and 2lbs (.907 kg) sodium chloride with the solution pH adjusted to 3.5 withsulfuric acid by slowly adding the latex to the water/salt solution. Thecoagulum was washed twice with RO water and dried at 60° C. (140° F.) ina forced air oven.

EXAMPLE III Preparation of Polystyrene Reinforced Polyisoprene Gels(PI-PS Core-Shell Particle C)

A 10 gallon (37.85 liter) reactor equipped with two axial flow turbinesoperating at 220 rpm was evacuated for 30 minutes and then charged witha soap solution composed of 41.6 lbs (18.87 kg) of reverse osmosis (RO)water, 24.8 grams of tripotassium phosphate, 6.21 lbs (2.82 kg) of a 10%solution of C14-18 unsaturated fatty acid potassium salt, 235 grams of a20% solution of the potassium salt of disproportionated rosin acid, 51.4grams of a 47.5% active dispersion of sodiumnaphthalenesulfonate-formaldehyde. The pH of the soap solution wasadjusted to 10.5-11.0 with a 20% potassium hydroxide solution.

Then, 17.3 lbs (7.85 kg) of isoprene and 6.49 lbs (2.94 kg) of 55%divinyl benzene were then added to the reactor. The reactor was heatedto 65° C. (149° F.). When the contents of the reactor reached 65° C.(149° F.), 17.3 grams of potassium persulfate dissolved in 432 grams ofwater was added. The reaction was allowed to proceed until the solidscontent reached full conversion (˜30% solid). The reactor was thencharged with 1080 grams of styrene and 1.73 grams of potassiumpersulfate dissolved in 43.2 grams of water. The reaction was allowed toproceed until 100% conversion of the monomer at about 32% solids andstopped by addition of 43.2 grams of 15% activeN-isopropylhydroxylamine. The latex was degassed and steam strippeduntil the residual isoprene level was less than 500 parts per million(ppm).

To the latex was added about I% of total weight of polymers tri(mixedmono & dinonylphenyl)phosphite antioxidant. The latex was thencoagulated in a solution of 120 lbs (54.43 kg) RO water at ˜70° C.(˜158° F.) and 4 lbs (1.81 kg) sodium chloride with the solution pHadjusted to 3.5 with sulfuric acid by slowly adding the latex to thewater/salt solution. The coagulum was washed twice with RO water anddried at 60° C. (140° F.) in a forced air oven.

EXAMPLE IV Preparation of Polyisoprene Control Sample Core (Particle D)

A 10 gallon (37.85 liter) reactor equipped with two axial flow turbinesoperating at 220 rpm was evacuated for 30 minutes and then charged witha soap solution composed of 41.6 lbs (18.87 kg) of reverse osmosis (RO)water, 24.8 grams of tripotassium phosphate, 6.21 lbs (2.82 kg) of a 10%solution of C14-18 unsaturated fatty acid potassium salt, 235 grams of a20% solution of the potassium salt of disproportionated rosin acid, 51.4grams of a 47.5% active dispersion of sodiumnaphthalenesulfonate-formaldehyde. The pH of the soap solution wasadjusted to 10.5-11.0 with a 20% potassium hydroxide solution.

Then, 17.3 lbs (7.85 kg) of isoprene and 6.49 lbs (2.94 kg) of 55%divinyl benzene were then added to the reactor. The reactor was heatedto 65° C. (149° F.). When the contents of the reactor reached 65° C.(149° F.), 17.3 grams of potassium persulfate dissolved in 432 grams ofwater was added. The reaction was allowed to proceed until 100%conversion of the monomer at about 30% solids and stopped by addition of43.2 grams of 15% active N-isopropylhydroxylamine. The latex wasdegassed and steam stripped until the residual isoprene level was lessthan 500 parts per million (ppm).

To the latex was added about 1% of total weight of polymers tri(mixedmono & dinonylphenyl)phosphite antioxidant. The latex was thencoagulated in a solution of 120 lbs (54.43 kg) RO water at 70° C. (158°F.) and 4 lbs (1.81 kg) of sodium chloride with the solution pH adjustedto 3.5 with sulfuric acid by slowly adding the latex to the water/saltsolution. The coagulum was washed twice with RO water and dried at 60°C. (140° F.) in a forced air oven.

EXAMPLE V Compounded Properties of Modified PI Gels

Particles A, B, C and D were evaluated in a formula containing 100 phrSBR 1502, 50 phr carbon black and a standard sulfur cure package. Allthe results are listed in Table 1. The polystyrene modified particles(particle A versus particle B) clearly showed improved mechanicalproperties (G′ at 1% and 300% modulus) and trouser tear property. Theparticles synthesized under hot conditions at 50° C. (122° F.) alsoshowed some improvement over particles obtained under cold conditions at10° C. (50° F.) (particle D vs. particle B). All the samples were curedat 160° C. (320° F.) for 30 minutes. TABLE 1 Particle B Particle DControl Particle A (reference) Particle C (reference) SBR 1502 100 100100 100 100 CB 50 50 50 50 50 PARTICLE A 0 25 0 0 0 PARTICLE B 0 0 25 00 PARTICLE C 0 0 0 25 0 PARTICLE D 0 0 0 0 25 SANTOFLEX 13 AO 2 2 2 2 2STEARIC ACID 3 3 3 3 3 ZINC OXIDE 3 3 3 3 3 NON-PRODUCTIVE 158 183 183183 183 NON-PRODUCTIVE 158 183 183 183 183 SULFUR 1.5 1.6 1.6 1.6 1.6TBBS 0.7 0.75 0.75 0.75 0.75 PRODUCTIVE 160.2 185.35 185.35 185.35185.35 RPA - Test 505 (160° C., 30 min) G′ @ 1% Strain (1 Hz, KPa)) 23052130 1941 2292 2189 G′ @ 10% Strain (1.0 Hz, KPa) 1414 1470 1399 15491552 G′ @ 50% Strain (1 Hz, KPa) 955 1043 1039 1081 1128 Tan D @ 10%Strain (1.0 Hz.) 0.17 0.15 0.14 0.15 0.14 T90 (min) 18.14 19.62 19.6618.43 17.52 Rheometer - MDR tc 90 (min) 15.49 16.57 17.79 17.26 17.05Delta Torque (MD) 15.4 16.8 15.5 16.5 17.0 Ring Tensile (ASTM D412, DIN53504) 100% Modulus (MPa) 2.3 2.7 2.7 2.8 2.8 200% Modulus (MPa) 5.1 5.35.4 5.6 5.6 300% Modulus (MPa) 11.1 10.6 10.6 11.2 11.4 Break Strength(MPa) 24.4 20.2 19.6 19.9 19.5 Elongation @ break (%) 509 471 460 465444 Hardness RT 74 78 74 80 77 Hardness 100 C 61 63 63 64 64 Rebound @RT (%) 41 29 37 30 31 Rebound @ 100 C (%) 49 51 54 50 52 Delta Rebound 823 17 20 22 Strebler Adhesion Steady State Average Load (RT, N) 135 138121 140 122 Steady State Average Load (95C, N) 168 126 128 126 110Mooney - Aged - 1 day ML4 @ 1 day 93 76 79 81 79 Din Abrasion - OriginalDensity (mg/mm³) 1.132 1.104 1.095 1.104 1.1 Rel Volume Loss (mm³) 91122 103 104 126 Tear Strength Tear Strength, ppi (Die C, N/mm) 55.0 46.548.6 46.8 48.4 Tear Strength, ppi (Trouser, N/mm) 16.1 16.0 10.4 14.714.5

As is apparent from the data of Table 1, the rubber compositionscontaining gel particle A to D show significant increase in deltarebound, in comparison with the control compound. In addition, the tearproperties were significantly increased in the case of compounds withmodified PI gel particle A and C with core-shell structure, whilecompounds with reference particle B and D deteriorate the tearproperties remarkably.

EXAMPLE VI Compounded Properties of Modified SBR Gels

A series of polystyrene modified SBR gels were synthesized using similarprocedures described in Example 1 and 3. The core and shell compositionsare listed in Table 2. All the samples are cured at 160° C. (320° F.)for 30 minutes. The compounded properties are shown in Table 3. Similartrend is observed in Table 3 that modified SBR gels provided enhancementin delta rebound and tear strength. TABLE 2 Core Shell Tg (° C.) SampleButadiene Styrene DVB Styrene Particle E (%) 50 50 10 0 −5 Particle F(%) 60 40 18 10 −5 Particle G (%) 50 50 7 10 −13 Particle H (%) 50 50 1010 0

TABLE 3 Particle E Control (Reference) Particle F Particle G Particle H4002 4006 4008 4009 4010 SBR 1502 100 100 100 100 100 CB 805 50 50 50 5050 PARTICLE E 0 25 0 0 0 PARTICLE F 0 0 25 0 0 PARTICLE G 0 0 0 25 0PARTICLE H 0 0 0 0 25 SANTOFLEX 13 AO 2 2 2 2 2 STEARIC ACID 3 3 3 3 3ZINC OXIDE 3 3 3 3 3 NON-PRODUCTIVE 158 183 183 183 183 NON-PRODUCTIVE158 183 183 183 183 SULFUR 1.5 1.5 1.5 1.5 1.5 TBBS 0.7 0.7 0.7 0.7 0.7PRODUCTIVE 160.2 185.2 185.2 185.2 185.2 RPA - Test 505 (cured at 160°C.) G′ @ 1% Strain (1 Hz, KPa) 2053 1837 1947 1708 1812 G′ @ 10% Strain(1 Hz, KPa) 1263 1279 1389 1205 1276 G′ @ 50% Strain (1 Hz, KPa) 834 903950 891 909 Tan D @ 10% Strain (1 Hz, KPa) 0.17 0.14 0.14 0.14 0.14Rheometer - MDR tc 90 (min) 16.1 19.8 19.6 20.0 20.0 Delta Torque (MD)14.8 14.7 15.5 13.7 14.8 Ring Tensile (ASTM D412, DIN 53504) 100%Modulus (MPa) 2.0 2.3 2.5 2.2 2.4 200% Modulus (MPa) 4.5 4.3 4.5 4.1 4.5300% Modulus (MPa) 9.9 8.7 9.0 8.4 9.2 Break Strength (MPa) 23.7 20.320.1 19.4 20.1 Elongation @ break (%) 519 515 508 504 501 Hardness RT 7275 78 71 76 Hardness 100 C 60 60 62 59 61 Rebound @ RT (%) 41 28 31 3027 Rebound @ 100 C (%) 49 51 50 52 52 Delta Rebound 8 24 19 22 24Strebler Adhesion Steady State Average Load (RT, N) 154 141 154 132 144Steady State Average Load (95C, N) 149 128 174 109 122 Mooney - Aged - 1day ML4 @ 1 day 78 74 75 76 75 Din Abrasion Density (mg/mm³) 1.124 1.1011.098 1.097 1.099 Rel Volume Loss (mm³) 97 115 120 101 116 Tear StrengthTear Strength, ppi (Die C, N/mm) 56.0 48.1 49.6 45.9 48.0 Tear Strength,ppi (Die TR, N/mm) 17.1 17.1 20.3 14.7 18.0

Variations in the present invention are possible in light of thedescription of it provided herein. While certain representativeembodiments and details have been shown for the purpose of illustratingthe subject invention, it will be apparent to those skilled in this artthat various changes and modifications can be made therein withoutdeparting from the scope of the subject invention. It is, therefore, tobe understood that changes can be made in the particular embodimentsdescribed which would be within the full-intended scope of the inventionas defined by the following appended claims.

1. A rubber composition which is comprised of a rubbery polymer and acore-shall particle which is comprised of (1) a crosslinked elastomericcore comprised of repeat units that are derived from at least onediolefin monomer, and (2) a polymeric shell which is derived from atleast one vinyl aromatic monomer.
 2. A rubber composition as specifiedin claim 1 wherein the core-shell particle is present at a level whichis within the range of about 1 phr to about 50 phr.
 3. A rubbercomposition as specified in claim 1 wherein the core-shell particle ispresent at a level which is within the range of about 20 phr to about 30phr.
 4. A rubber composition as specified in claim 2 wherein at leastone crosslinking monomer is present in the crosslinked elastomeric coreat a level which is within the range of 15 weight percent to 25 weightpercent, based upon the weight of the crosslinked elastomeric core.
 5. Arubber composition as specified in claim 4 wherein the rubbery polymeris styrene-butadiene rubber.
 6. A rubber composition as specified inclaim 4 wherein the rubbery polymer is polybutadiene rubber.
 7. A rubbercomposition as specified in claim 1 wherein the crosslinked elastomericcore is further comprised of repeat units that are derived from one ormore vinyl aromatic monomers.
 8. A rubber composition as specified inclaim 4 wherein crosslinked elastomeric core is a polymeric compositionhaving a glass transition temperature which is within the range of −20°C. to 20° C.
 9. A rubber composition as specified in claim 8 wherein thepolymeric shell is comprised of a polymeric composition having a glasstransition temperature which is within the range of 50° C. to 160° C.10. A rubber composition as specified in claim 9 wherein the glasstransition temperature of the elastomeric core differs from the glasstransition temperature of the polymeric shell by at least 30° C.
 11. Arubber composition as specified in claim 10 wherein the diolefin monomeris isoprene.
 12. A rubber composition as specified in claim 11 whereinthe vinyl aromatic monomer is styrene.
 13. A rubber composition asspecified in claim 12 wherein the crosslinking monomer is divinylbenzene.
 14. A rubber composition as specified in claim 13 wherein thepolymeric shell is comprised of a polymeric composition having a glasstransition temperature which is within the range of 50° C. to 160° C.15. A rubber composition as specified in claim 14 wherein the glasstransition temperature of the elastomeric core differs from the glasstransition temperature of the polymeric shell by at least 70° C.
 16. Arubber composition as specified in claim 15 wherein the weight ratio ofthe core to the shell is within the range of 12:1 to 8:1.
 17. A rubbercomposition as specified in claim 1 wherein the glass transitiontemperature of the elastomeric core differs from the glass transitiontemperature of the polymeric shell by at least 50° C. and wherein theweight ratio of the core to the shell is within the range of 20:1 to1:1.
 18. A rubber composition as specified in claim 1 wherein the glasstransition temperature of the elastomeric core differs from the glasstransition temperature of the polymeric shell by at least 70° C. andwherein the weight ratio of the core to the shell is within the range of15:1 to 5:1.
 19. A rubber composition as specified in claim 1 whereinthe shell is comprised of at least 75 weight percent repeat units thatare derived from a vinyl aromatic monomer.
 20. A rubber composition asspecified in claim 2 wherein the shell is comprised of at least 85weight percent repeat units that are derived from a vinyl aromaticmonomer.